Method for producing an american petroleum institute standards group iii base stock from vacuum gas oil

ABSTRACT

A method for producing an American Petroleum Institute Standards Group III Base Stock from vacuum gas oil, by injecting hydrogen, heating, saturating the mixture through hydrogen reactors connected in series with a liquid hourly space velocity (LHSV)−1 from 0.5 to 2.5, forming a saturated heated base oil, and coproduct. The method fractionates the saturated heated base oil while simultaneously refluxing a cooled light oil fraction forming an American Petroleum Institute Standards Group III Base Stock with less than 0.03% sulfur, with greater than 90% saturates and a viscosity index greater than 120 as defined by ASTM D-2270, a viscosity from 2 to 10 centistokes as defined by ASTM D-445 a boiling point range from 600 degrees F. to 1050 degrees F. as defined by ASTM D-86, and a cold crank viscosity (CCS) between 1200 and 5000 centipoise at minus 25 degrees C. and as defined by ASTM D-5293.

CROSS REFERENCE TO RELATED APPLICATIONS

The application claims the benefit of related patent application of U.S.patent application Ser. No. 62/593,002 titled “System for producing anAmerican Petroleum Institute Standards Group III Base Stock from vacuumgas oil” and U.S. patent application Ser. No. 62/593,030 Method forProducing an American Petroleum Institute Standards Group III Base Stockfrom vacuum gas oil” both filed Nov. 20, 2017 and incorporated herein intheir entirety.

FIELD

The present embodiment generally relates to a method for producing anAmerican Petroleum Institute Standards Group III base stock from vacuumgas oil.

BACKGROUND

A need exists for a method for producing an American Petroleum InstituteStandards Group III Base Stock from vacuum gas oil.

The present embodiments meet these needs.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description will be better understood in conjunction withthe accompanying drawings as follows:

FIG. 1 is a diagram of equipment usable in the method for the productionof American Petroleum Institute Standards Group III base stock from usedoil.

FIG. 2 is a diagram of another embodiment of equipment usable in themethod for producing American Petroleum Institute Standards Group IIIbase stock from used oil.

FIG. 3 is a diagram of another embodiment of equipment usable in themethod for producing American Petroleum Institute Standards Group IIIbase stock from used oil.

FIG. 4 is a diagram of a fresh hydrogen injector.

FIG. 5 is a diagram of a recycle hydrogen injector and associatedcomponents.

FIG. 6 depicts a first sequence of steps according to the method.

FIG. 7 depicts a second sequence of steps according to the method.

FIG. 8 depicts a third sequence of steps according to the method.

The present embodiments are detailed below with reference to the listedFigures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The invention teaches a method of producing an American PetroleumInstitute Standards Group III Base Stock from used oil in the form ofvacuum gas oil.

The embodiments will enable an increase in inventory of AmericanPetroleum Institute Standards Group III Base Stock.

The embodiments will save lives because re-refining reduces unnecessaryair pollution caused by burning used oil in space heaters which are notadequately maintained.

The embodiments reduce environmental pollution by providing a safe andresponsible way to manage used oils. One gallon of used oil cancontaminate over one million gallons of drinking water. Additionally,re-refining used oil requires between 50%-80% less energy to producebase oil compared to conventional production from crude oil.

The embodiments reduce dependence on fossil fuel because used oil can bebeneficially re-refined to produce high-purity base oil fit for originalpurpose.

The embodiments create a base oil needed for high performance engineswhich require better fuel economy and lower emissions of Green HouseGases and particulate matter. The resultant improvement in ambient airquality reduces negative health impacts, especially to the mostvulnerable population—older citizens and young children.

The embodiments increase inventory of American Petroleum InstituteStandards Group III Base Stock.

The embodiments reduce pollution to the improper disposal of used oilinto ground water. 1 gallon of used oil can contaminate 1 milliongallons of drinking water.

Before explaining the present method in detail, it is to be understoodthat the method is not limited to the particular embodiments and that itcan be practiced or carried out in various ways.

The invention relates to a method for producing an American PetroleumInstitute Standards Group III Base Stock from vacuum gas oil by threesequences.

In all three sequences, hydrogen is injected using two differentinjectors into a vacuum gas oil or mixture of vacuum gas oil andpetroleum derived product, the hydrogen increasing pressure on themixture to between 1000 psig and 1500 psig.

A series of heaters are then used to increase temperature of the mixtureor of the vacuum gas oil to 600 degrees Fahrenheit, saturating thevacuum gas oil through a plurality of hydrogen reactors connected inseries having a liquid hourly space velocity (LHSV)⁻¹ through thehydrogen reactors from 0.5 to 2.5, forming a saturated heated base oil,a coproduct and contaminants.

Multiple additional heaters and multiple additional hydrogen reactorscan be used in series.

A fractionation tower receives and fractionates the heated saturatedheated base oil to remove a light oil fraction with a boiling point ofless than 600 degrees Fahrenheit while simultaneously refluxing a cooledlight oil fraction during fractionating, forming an American PetroleumInstitute Standards Group III Base Stock with less than 0.03 percentsulfur, greater than 90 percent saturates and a viscosity index greaterthan 120 as defined by ASTM D-2270 and a viscosity range from 2centistokes to 10 centistokes as defined by ASTM D-445 with a boilingrange from 600 degrees Fahrenheit to 1050 degrees Fahrenheit as definedby ASTM D-86, and a cold crank viscosity (CCS) from 1200 to 5000centipoise at minus 25 degrees Celsius and as defined by ASTM D-5293.

The following terms are used herein:

ASTM D445-17a: American Society for Testing and Materials (ASTM)D445-17(a) published on May 1, 2017 is the standard method for testingkinematic viscosity of petroleum products both transparent and opaqueliquids. Results are reported in cPs at 40° C. and 100° C.

ASTM D-2270-10: American Society for Testing and Materials (ASTM) D2270-10 published on Jan. 1, 2016 is the standard method for calculatingviscosity index (VI) of petroleum products from kinematic viscositiesreported at 40° C. and 100° C.

ASTM D5293-17a: American Society for Testing and Materials (ASTM)D5293-17(a) published on Oct. 1, 2017 is the standard test to determinethe apparent viscosity of engine oils and base oils at temperaturesbetween minus 5 and minus 35° C. at high shear rates. Reported asdynamic or absolute viscosity, centipoise (cP).

ASTM D86-18: American Society for Testing and Materials (ASTM) D86-17published on May 1, 2017 is the standard test to determine thedistillation range of Petroleum Products and Liquid Fuels at Atmosphericpressure.

The term “conduit” as used herein is a channel for conveying fluids.Also referred to as a mixing conduit when multiple fluids are combined

The term “Cold Crank Simulation” refers to a method used to determinethe low temperature performance of lubricants, when starting a coldengine (i.e. cold-cranking which physical property is termed “cold crankviscosity).

The term “contaminants” as used herein can comprise aromatics as well ascompounds containing sulfur, nitrogen and chlorine, such as hydrogensulfide (H2S), ammonia (NH3) or hydrochloric acid (HCL).

The term “contaminant free saturated heated base oil” refers to asaturated heated based oil after contaminants have been removed in thelow pressure flash drum.

The term “control meters” are precision made liquid measuringinstruments that maintain precise and accurate metering of fluids.

The term “control valve” is a valve used to control fluid flow byvarying the size of the flow passage as directed by a signal from acontroller. This enables the direct control of flow rate and theconsequential control of process quantities such as pressure,temperature, and liquid level.

The term “coproduct” as used herein can refer to a saleable, light oilfraction created during the saturation of the heated vacuum gas oilmixture. The term “Group III base stock” is defined by the AmericanPetroleum Institute as a base stock that is greater than 90 percentsaturates, less than 0.03 percent sulfur and has a viscosity index above120.

The term “cracked gas” as used herein refers the small percentage ofvery light hydrocarbons, usually existing in a gaseous form, which are aresult of the breakdown of more complex, long-chain hydrocarbons such asvacuum gas oil and saturated, heated base oil.

The term “demetalizing catalyst” refers to a catalyst designed toselectively reduce specific metals such as phosphorous which mayotherwise deposit on downstream catalysts, poisoning the active sites.

The term “flash drum” is a vessel used to separate a vapor-liquidmixture. A flash drum may also be referred to as a vapor-liquidseparator, breakpot, knock-out drum or knock-out pot, compressor suctiondrum. It can operate at high pressure or low pressure.

The term “fractionation tower” is an essential item used in distillationof liquid mixtures so as to separate the mixture into its componentparts, or fractions, based on the differences in volatilities.

The term “a fuel oil fraction” as used herein can refer to a lighthydrocarbon, such as kerosene.

The term “heater” and/or “heating system” as used herein refers to thesystem or device that produces and radiates heat to raise thetemperature of a liquid, gas or mixture. Examples may include directfired heaters, heat exchangers of various styles, feed effluent heatexchangers, hot oil heaters, heater coils and such.

The term “heating the vacuum gas oil mixture” as used herein can referto increasing an initial temperature of the vacuum gas oil mixture to atleast 450 degrees, such as using an exchanger or a direct fired heater.

The term “hydrogen compressor” is a mechanical device that increases thepressure of hydrogen gas by reducing its volume.

The term “hydrogen reactor” as used herein is a pressure vessel in whichhydrogen is used in a catalytic chemical process to remove contaminantssuch as sulfur and nitrogen from refined petroleum products, such asvacuum gas oil.

The term “hydrogen vaporizer” is a device which vaporizes liquidhydrogen.

The term “initial boiling point” as used herein can refer to therecorded temperature of the first drop of distilled vapor that iscondensed and falls from the end of a condenser during distillation asdefined by ASTM D-86.

The term “injector” is a mechanical device that increases the pressureof a gas by reducing its volume.

The term “light oil fraction” as used herein can refer to a lighthydrocarbon, such as kerosene.

The term “liquid hourly space velocity” is defined as the hourly feedrate flow divided by the volume of catalyst.

The term “liquid hydrogen” is the liquid (cryogenic) state of theelement hydrogen.

The term “metallic catalyst” is a substance that contains various metalssuch as nickel, cobalt, molybdenum which are usually supported on ametal oxide base. Catalysis is the process of increasing the rate of achemical conversion by adding a substance known as a catalyst, which isnot consumed in the catalyzed reaction and can continue to actrepeatedly. Different metal combinations may be used to achieve thedesired reaction.

The term “mixture” as used herein can refer to a substance made bymixing other substances together which may be soluble.

The term “naptha” is a distillation product boiling in the approximaterange 100-200° C. and containing aliphatic hydrocarbons: Naptha is foundas a component of solvents, as well as Kerosene and Gasoline.

The term “petroleum derived product” refers to a product that includeswax and oil with a viscosity index greater than 120 and wherein thepetroleum derived product has a viscosity from 2 to 10 centistokes at100 degrees Celsius as defined by ASTM D-445, and a viscosity index (VI)from 120 to 160 as defined by ASTM D-2270.

The term “plurality of hydrogen reactors” as used herein can refer totwo or more hydrogen reactors, such as from 2 to 6 hydrogen reactorsconnected in series with increasing temperature in each hydrogenreactor. Each hydrogen reactor can have a “reactor volume”. The reactorvolume can be the expressed quantity in cubic feet of catalyst that iscontained by the hydrogen reactor for each of the plurality of hydrogenreactors. In some examples, the plurality of hydrogen reactors can eachhave identical reactor volumes.

The term “recycle nozzle” is a device which injects recycled hydrogeninto a conduit.

The term “recycle overhead” refers to a recycled hydrogen stream.

The term “refluxing” as used herein can refer to a technique involvingthe condensation of vapors and the return of condensate to the systemfrom which it originates.

The term “random packed tower” is a distillation tower (or column) thathas both trays and packed section internals. This could be 4 trays and 3packed sections

The term “saturates” means the fraction that consists of nonpolarmaterial including linear, branched, and cyclic saturated hydrocarbons(paraffins).

The term “saturated heated base oil” refers to a hydrocarbon chain thathas been heated, and has had the double and triple bonds between itscarbon atoms broken and replaced with single bonds and hydrogen atoms.

The term “saturating the heated vacuum gas oil mixture” as used hereincan refer to removing at least 90 percent of aromatic hydrocarbons, andaromatic alkanes, including toluene, xylene, and benzene.

The term “turbulent flow” is defined as flow of a fluid in which itsvelocity at any point varies rapidly in an irregular manner.

The term “used oil” as used herein can refer to any oil, which issynthetic oil or derived from crude oil, that has undergone a process,such as use in an engine, machine or any other device, which breaks downthe properties of the oil during heating and mechanical operation. Aused oil can be an oil used as a lubricant, a coolant or a heat transfermedia.

The term “vacuum gas oil” as used herein can refer to oils purified byvacuum distillation process. This definition refers to used oils.

The term “velocity” is a measure of the rate of motion of a bodyexpressed as the rate of change of its position in a particulardirection with time. It is measured in meters per second, miles per houror feet per second.

The term “viscosity” is a measure of an oil's resistance to flow Itgoverns the sealing effect of oils and the rate of oil consumption, aswell as determines the ease with which machines may be started oroperated under varying temperature conditions, particularly in coldclimates.

The term “viscosity index” as used herein can refer to the rate ofchange of a fluid's viscosity with changes with temperature as definedby ASTM D-2270.

The term “water cooled exchanger/cooling water exchanger” is a coolingsystem to remove heat from processes or equipment. Heat removed from onemedium is transferred to another medium, or process fluid. Most often,the cooling medium is water.

The invention relates to a method for producing an American PetroleumInstitute Standards Group III base stock from vacuum gas oil derivedfrom used oil.

The method includes the step of combining a petroleum derived producthaving a viscosity index greater than 120 into a vacuum gas oil derivedfrom used oil forming a vacuum gas oil mixture with a combined boilingpoint range from 450 degrees F. to 1050 degree F. as defined by ASTMD-86.

In method includes the step of increasing temperature of the vacuum gasoil mixture to a temperature from 450 degrees Fahrenheit to 600 degreesFahrenheit, forming a heated vacuum gas oil mixture while simultaneouslyincreasing pressure on the heated vacuum gas oil mixture from 50 psig toa pressure from 1000 psig and 1500 psig by injection of hydrogen.

The method includes the step of saturating the heated vacuum gas oilmixture forming a first partially saturated heated base oil then a fullysaturated heated base with hydrogen through a plurality of hydrogenreactors connected in series, having a liquid hourly space velocity(LHSV)⁻¹ through the hydrogen reactors from 0.5 to 2.5.

The method includes the step of separating a saturated heated base oilfrom a recycle overhead at a high pressure from 1000 psig to 1500 psigand removing contaminants from the saturated heated base oil producingcontaminant free saturated heated base oil.

The method also includes the step of fractionating the contaminant freesaturated heated base oil using steam to remove a light oil fractionwith an initial boiling point less than 600 degrees F. whilesimultaneously refluxing, forming an API Standards Group III Base Stockwith less than 0.03 percent sulfur, greater than 90 percent saturatesand a viscosity index greater than 120 as defined by ASTM D-2270 and aviscosity range from 2 to 10 centistokes as defined by ASTM D-445 with aboiling range from 600 degrees F. to 1050 degrees F. as defined by ASTMD-86, and a cold crank viscosity (CCS) between 1200 and 5000 centipoiseat minus 25 degrees C. and as defined by ASTM D-5293.

In embodiments, the invention can also include the step of exchangingenergy from the American Petroleum Institute Standards Group III BaseStock 113 is with the feedstock vacuum gas oil reducing temperature ofthe American Petroleum Institute Standards Group III base stock from 500degrees Fahrenheit to 300 degrees Fahrenheit using a feed effluent heatexchanger.

In embodiments, the invention can also include the step of receiving awarm American Petroleum Institute Standards Group III Base Stock fromthe feed effluent heat exchanger 100 and cools 100 degrees Fahrenheit to150 degrees Fahrenheit and cooling using a cooling water exchanger andtransferring the cooled American Petroleum Institute Standards Group IIIBase Stock to storage or transport.

In embodiments, hydrogen can be injected using a fresh hydrogen injectorcomprising a nozzle that engages a flow control valve further incommunication with a flow meter and a high pressure pump and a hydrogenvaporizer for receiving liquid hydrogen from a liquid hydrogenreservoir.

In embodiments, each hydrogen reactor can increase the temperature ofthe saturated heated base oil in each hydrogen reactor by a minimum of 5percent.

In embodiments, the invention can include the step of using a metalliccatalyst in each of the hydrogen reactors, wherein the metallic catalystis selected from at least one of the group consisting of: cobalt,nickel, and molybdenum.

In embodiments, the separating of the saturated heated base oil from therecycle hydrogen can be performed using high pressure flash drum.

In embodiments, the invention can include the step of using a recyclehydrogen injector to inject hydrogen into a heated vacuum gas oilmixture which includes a recycle nozzle, a recycle flow meter connectedto the recycle nozzle in series, a hydrogen compressor connected to therecycle flow meter, a second stage knockout drum separating contaminatedwater, a first stage knockout drum separating contaminated water andnaptha, a water cooled exchanger, a high pressure wash water injectorproviding a psig from 1400 to 1600 psig receiving water, and a recycleoverhead connected to the high pressure wash water injector.

Turning now to the Figures, FIG. 1-FIG. 3 are diagrams of equipmentusable by the method for the production of American Petroleum InstituteStandards Group III base stock from vacuum gas oil.

The system uses a fresh hydrogen injector for injecting hydrogen intothe vacuum gas oil mixture and raising pressure in the conduit tomaintain a pressure between 1000 psig and 1500 psig.

The system also uses a recycle hydrogen injector introducing injectingrecycle hydrogen at an elevated pressure and raising pressure in theconduit to maintain a pressure between 1000 psig and 1500 psig on thevacuum gas oil mixture.

The system can have a conduit 10 for receiving a petroleum derivedproduct 20 having a viscosity index greater than 120. The conduit 10receives a vacuum gas oil 22 derived from used oil forming a vacuum gasoil mixture 24 with a combined boiling point range from 450 degreesFahrenheit to 1050 degree Fahrenheit as defined by ASTM D-86.

A first heater 30 can be fluidly connected to the conduit 10 and to afirst hydrogen reactor 32 for increasing temperature on the vacuum gasoil mixture 24 to 450 degrees Fahrenheit at a pressure between 1000 psigand 1500 psig, partially saturating the vacuum gas oil mixture 24. Inembodiments, prior to the first heater 30, a pump 25 transfers vacuumgas oil mixture 24 to the first heater.

A heated vacuum gas oil mixture 19 is shown positioned right above thefirst heater 30.

A first hydrogen reactor 32 creates a partially saturated heated baseoil 34. A second heater 40 can be fluidly connected to the firsthydrogen reactor 32, and a second hydrogen reactor 42 can furtherincrease temperature of the partially saturated heated base oil 34.

A third heater 50 can be fluidly connected to the second hydrogenreactor 42 and to a third hydrogen reactor 52, increasing temperature toa third temperature of 600 degrees Fahrenheit and to a third pressure of1000 psig forming a saturated heated base oil 134.

In embodiments, a high pressure flash drum 60 can be connected to thethird hydrogen reactor 52 for separating contaminants from the saturatedheated base oil 62 and coproduct 64 at a high pressure from 1000 psig to1500 psig.

A recycle overhead 55 can be connected to the high pressure flash drum60, receiving high pressure recycle hydrogen and contaminants separatedfrom the saturated heated base oil in the high pressure flash drum.

A low pressure flash drum 70 can be connected to the high pressure flashdrum 60.

The low pressure flash drum 70 can have a pressure from 40 psig to 60psig thereby decreasing pressure on the saturated heated base oil 62 andcoproduct 64 while removing contaminants 63.

In another embodiment, the system can use a mixing conduit 75 forreceiving a petroleum derived product 20 (shown in FIG. 2) instead ofreceiving the petroleum derived product through the conduit 10 shown inFIG. 1. In this alternative embodiment shown in FIG. 2, the petroleumderived product 20 has a viscosity index greater than 120.

A fourth heater 80 can be fluidly connected to the low pressure flashdrum 70 for heating the saturated heated base oil 62 and coproduct 64forming a heated saturated heated base oil 82, which is shown in FIGS.1-3, having a boiling point from 600 degrees F. to 1050 degreesFahrenheit as defined by ASTM D-86.

In embodiments, a fifth heater 85 can be used as shown in FIG. 3. Thefifth heater preheats a petroleum derived product 20 having a viscosityindex greater than 120 to a temperature between 400 degrees Fahrenheitand 600 degrees Fahrenheit prior to introducing the preheated petroleumderived product into the mixing conduit 75.

FIGS. 1-3 show a fractionation tower 90 receiving steam 108 andfractionating the saturated heated base oil 82 to remove a light oilfraction 111 with a an initial boiling point less than 600 degreesFahrenheit while simultaneously refluxing a cooled light oil fraction111 during fractionating forming an American Petroleum InstituteStandards Group III Base Stock 113 with less than 0.03 percent sulfur,greater than 90 percent saturates and a viscosity index greater than 120as defined by ASTM D-2270 and a viscosity range from 2 to 10 centistokesas defined by ASTM D-445 with a boiling range from 600 degrees F. to1050 degrees F. as defined by ASTM D-86, and a cold crank viscosity(CCS) from 1200 to 5000 centipoise at minus 25 degrees C. and as definedby ASTM D-5293.

The fractionation tower 90 removes steam 108 and a cracked gas 107.

The steam 108 flow out of the fractionation tower and is condensed in acondenser 110 into steam condensate 109.

In embodiments, energy from the American Petroleum Institute StandardsGroup III Base Stock is exchanged with the feedstock vacuum gas oilreducing temperature of the American Petroleum Institute Standards GroupIII base stock from 500 degrees Fahrenheit to 300 degrees Fahrenheitusing a feed effluent heat exchanger 100.

A cooling water exchanger 102 receives warm American Petroleum InstituteStandards Group III Base Stock 113 from the feed effluent heat exchanger100 and reduces temperature from 300 degrees Fahrenheit to 150 degreesFahrenheit, before transfer to storage or transport.

In embodiments, each hydrogen reactor increases the fluid temperaturecontained therein by a minimum of 5 percent.

In embodiments, a metallic catalyst 38 a-38 c, can be inserted in eachof the hydrogen reactors, wherein the metallic catalyst is selected fromat least one of the group consisting of: cobalt, nickel, and molybdenum.

In embodiments, high pressure flash drums or low pressure flash drumscan be used for separation.

Also shown in FIGS. 1-3 are a recycle nozzle 37, a recycle hydrogeninjector 35, and a fresh hydrogen injector 26.

FIG. 4 is a diagram of the fresh hydrogen injector 26.

A fresh hydrogen injector 26 can inject hydrogen and raise pressure inthe conduit 10 to maintain between 1000 psig and 1500 psig on the vacuumgas oil mixture 24.

The fresh hydrogen injector 26 includes a nozzle 27 that engages a flowcontrol valve 28 that is further in communication with a flow meter 29and a high pressure pump 31 and a hydrogen vaporizer 33 for receivingliquid hydrogen from a liquid hydrogen reservoir 36.

In embodiments, a recycle flow meter 39 can be connected to the recyclenozzle 37 in series.

FIG. 5 is a diagram of the recycle hydrogen injector and associatedcomponents.

A recycle hydrogen injector 35 can inject recycled hydrogen at anelevated pressure and raise pressure on the vacuum gas oil mixture tomaintain pressure in the conduit 10 between 1000 psig and 1500 psig.

The recycle hydrogen injector 35 includes a recycle nozzle 37, a recycleflow meter 39 connected to the recycle nozzle in series, a hydrogencompressor 41 connected to the recycle flow meter 39, a second stageknockout drum 43 separating out contaminated water 45, a first stageknockout drum 47 separating out contaminated water and naptha 49, awater cooled exchanger 51, a high pressure wash water injector 53 havinga psig from 1400 psig to 1600 psig, and a recycle overhead 55 connectedto the high pressure flash drum 60 receiving high pressure recyclehydrogen and contaminants 63 separated from oil in high pressure flashdrum.

The fresh hydrogen injector 26 is shown in this Figure.

FIG. 6 depicts a first sequence of steps according to the method.

In this embodiment of the method for producing an American PetroleumInstitute Standards Group III base stock from vacuum gas oil derivedfrom used oil, Step 100 involves combining a petroleum derived producthaving a viscosity index greater than 120 into a vacuum gas oil derivedfrom used oil forming a vacuum gas oil mixture with a combined boilingpoint range from 450 degrees F. to 1050 degree F. as defined by ASTMD-86.

Step 102 involves heating the vacuum gas oil mixture to a temperaturefrom 450 degrees to 600 degrees F., forming a heated vacuum gas oilmixture while simultaneously increasing pressure on the heated vacuumgas oil mixture from 50 psig to a pressure from 1000 psig and 1500 psigby injection of hydrogen,

Step 104 involves saturating the heated vacuum gas oil mixture forming afirst partially saturated heated base oil then a fully saturated heatedbase with hydrogen through a plurality of hydrogen reactors connected inseries, having a liquid hourly space velocity (LHSV)⁻¹ through thehydrogen reactors from 0.5 to 2.5

Step 106 involves separating a saturated heated base oil from a recycleoverhead at a high pressure from 1000 psig to 1500 psig.

Step 108 involves removing contaminants from the saturated heated baseoil producing contaminant free saturated heated base oil.

Step 110 involves fractionating the contaminant free saturated heatedbase oil using steam to remove a light oil fraction with an initialboiling point less than 600 degrees F. while simultaneously refluxing,forming an API Standards Group III Base Stock with less than 0.03%sulfur, greater than 90% saturates and a viscosity index greater than120 as defined by ASTM D-2270 and a viscosity range from 2 to 10centistokes as defined by ASTM D-445 with a boiling range from 600degrees F. to 1050 degrees F. as defined by ASTM D-86, and a cold crankviscosity (CCS) between 1200 and 5000 centipoise at minus 25 degrees C.and as defined by ASTM D-5293.

In embodiments, energy from the API standards Group III base stock isexchanged with the feedstock vacuum gas oil reducing temperature of theAPI standards Group III base stock.

In embodiments, each hydrogen reactor increases the fluid temperaturecontained therein by a minimum of 5 percent.

In embodiments of the method a metallic catalyst can be used in each ofthe hydrogen reactors, wherein the metallic catalyst is selected from atleast one of the group consisting of: cobalt, nickel, molybdenum.

In embodiments of the method the separating of the saturated heated baseoil 34 from the recycle hydrogen is performed using high pressure flashdrums or low pressure flash drums.

FIG. 7 depicts a second sequence of steps according to the method.

In this embodiment of the method for producing an American PetroleumInstitute standards Group III base stock from vacuum gas oil, Step 200involves heating the vacuum gas oil to a temperature of from 450 degreesto 600 degrees Fahrenheit forming a heated vacuum gas oil whilesimultaneously increasing pressure on the vacuum gas oil by from 50 psigto between 1000 psig and 1500 psig, by injection of hydrogen using afresh hydrogen injector 26 and recycle hydrogen injector 35.

Step 202 involves saturating the heated vacuum gas oil through aplurality of hydrogen reactors connected in series, forming a saturatedheated base oil and a coproduct and contaminants.

Step 204 involves separating contaminants from the saturated heated baseoil and coproduct at a high pressure from 1000 psig to 1500 psig.

Step 206 involves combining a petroleum derived product having aviscosity index greater than 120 into the saturated heated base oil andcoproduct.

Step 208 involves heating the combined saturated heated base oil andcoproduct.

Step 210 involves fractionating the heated saturated base oil to removea light oil fraction with a an initial boiling point less than about 600degree F. while refluxing cooled light oil fraction into thefractionation tower at a predetermined location forming an API standardsGroup III base stock.

FIG. 8 depicts a third sequence of steps according to the method.

In this third embodiment of the method, for producing an AmericanPetroleum Institute standards Group III base stock from vacuum gas oil,Step 300 involves heating the vacuum gas oil blend to a temperature offrom 450 degrees to 600 degrees F. forming a heated vacuum gas oil whilesimultaneously increasing pressure on the vacuum gas oil by from 50 psigto between 1000 psig and 1500 psig, by injection of hydrogen using afresh hydrogen injector 26 and recycle hydrogen injector 35.

Step 302 involves saturating the heated vacuum gas oil through aplurality of hydrogen reactors connected in series, forming a saturatedheated base oil, coproduct, and contaminants.

Step 304 involves separating contaminants from the saturated heated baseoil and coproduct at a high pressure from 1000 psig to 1500 psig.

Step 306 involves heating the saturated base oil and coproduct forming aheated saturated base oil.

Step 308 involves combining a preheated petroleum derived product havinga viscosity index greater than 120 into the heated saturated base oil.

Step 310 involves fractionating the combined heated saturated base oilto remove a light oil fraction with a an initial boiling point less thanabout 600 degrees F. while refluxing cooled light oil fraction into thefractionation tower at a predetermined location forming an API standardsGroup III base stock.

Example 1

The method for producing an American Petroleum Institute Standards GroupIII Base Stock from vacuum gas oil, can use a conduit 10 for receiving apetroleum derived product 20 having a viscosity index greater than 120.

The conduit can be a 2 inch inner diameter metal pipe.

The conduit receives a vacuum gas oil 22 derived from used oil forming avacuum gas oil mixture 24 with a combined boiling point range from 450degrees Fahrenheit to 1050 degree Fahrenheit as defined by ASTM D-86.

The conduit supports a turbulent flow in the pipe.

The flow rate in the conduit can be 45 gallons a minute.

A fresh hydrogen injector 26 can continuously inject high purityhydrogen into the conduit and raise pressure in the conduit 10 tomaintain between 1000 psig and 1500 psig.

The fresh hydrogen injector can raise hydrogen partial pressure.

A recycle hydrogen injector 35 recirculates hydrogen from previouscycles in the system.

The recycle hydrogen injector increases velocity of the fluid in theconduit. It increases pressure by decreasing volume as the injectorinjects recycled hydrogen at an elevated pressure and raises pressure tomaintain pressure in the conduit 10 between 1000 psig and 1500 psig.

A first heater 30 such as a heat transfer fluid hot oil heat exchangerfluidly connected to the conduit 10 and to a first hydrogen reactor 32is used for increasing the vacuum gas oil mixture in temperature to 450degrees Fahrenheit at 1000 psig to 1500 psig.

Hydrogen saturation occurs in the presence of a first catalyst in thefirst hydrogen reactor which can be nickel, molybdenum, or cobaltsupported on alumina beads. The heated vacuum gas oil mixture is fullysaturated through a plurality of hydrogen reactors each with a similaror different catalyst, connected in series having a liquid hourly spacevelocity (LHSV)⁻¹ through the hydrogen reactors from 0.5 to 2.5, forminga saturated heated base oil, a coproduct, and contaminants. In someembodiments, a demetalizing catalyst can be used in the first hydrogenreactor in combination with the nickel, cobalt or molybdenum catalysts.

A second heater 40 is fluidly connected to the first hydrogen reactor 32and a second hydrogen reactor 42 having a second catalyst for furtherincreasing in temperature of the vacuum gas oil mixture; saturating theheated vacuum gas oil mixture through a plurality of hydrogen reactorsconnected in series having a liquid hourly space velocity (LHSV)⁻¹through the hydrogen reactors from 0.5 to 2.5; forming a saturatedheated base oil, a coproduct, and contaminants.

A third heater 50 is fluidly connected to the second hydrogen reactor 42and to a third hydrogen reactor 52 increasing the temperature of thevacuum gas oil mixture to a third temperature of 600 degrees Fahrenheitat a pressure between 1000 psig and 1500 psig.

The volume of the hydrogen reactors can be 250 cubic feet with acumulative total of all hydrogen reactors of 750 cubic feet.

The heaters are on temperature control providing constant temperature tothe hydrogen reactors.

A high pressure flash drum 60 connected to the third hydrogen reactor isused for separating remaining hydrogen and contaminants from theprocessed oil, which is known as the saturated heated base oil 62 andcoproduct 64 at a high pressure from 1000 psig to 1500 psig.

The coproduct in this example with vacuum gas oil can be a light oilfraction similar to kerosene or diesel fuel.

Vacuum gas oil fluid is controlled to maintain a specific level of fluidin a low pressure flash drum 70 connected to the high pressure flashdrum.

The low pressure flash drum 70 is used for decreasing the saturatedheated base oil and coproduct pressure to between 40 to 60 psig.

A fourth heater 80 is fluidly connected to the low pressure flash drumis used for heating the saturated base oil and coproduct, forming acontaminant free saturated heated base oil 82 having a boiling pointfrom 450 degrees Fahrenheit to 1050 degrees Fahrenheit as defined byASTM D-86. The fourth heater is similar to the first, second and thirdheaters.

A fractionation tower 90 is used that receives steam 108 and thecontaminant free saturated heated base oil 82.

In this example a four tray, three packed bed section can be used. Thisis a randomly packed tower under vacuum.

The fractionation tower runs at about 2 psia continuously and can be 46feet 9 inches feet tall. The diameter can be 5 feet 6 inches.

The flow rate through the fractionation tower is typically greater than98% of the flow of vacuum gas oil mixture 24 in conduit 10, onlydecreasing by the amount of contaminants removed.

A cracked gas 107, generated during the fractionation process, isremoved from the top of the tower, as shown in FIG. 1.

Steam 108 flows out the fraction tower via a conduit and is condensedinto steam condensate 109 in the condenser 110.

A light oil fraction 111 is pulled off the tower refluxed and cycledback into the tower.

The fractionation tower 90 receives and fractionates the contaminantfree saturated heated base oil 82 to remove a light oil fraction 111fraction with a an initial boiling point less than 600 degreesFahrenheit while simultaneously refluxing a cooled light oil fractionduring fractionating forming an American Petroleum Institute StandardsGroup III Base Stock with less than 0.03 percent sulfur, greater than 90percent saturates and a viscosity index greater than 120 as defined byASTM D-2270 and a viscosity range from 2 centistokes to 10 centistokesas defined by ASTM D-445 with a boiling range from 600 degreesFahrenheit to 1050 degrees Fahrenheit as defined by ASTM D-86, and acold crank viscosity (CCS) from 1200 centipoise to 5000 centipoise atminus 25 degrees Celsius and as defined by ASTM D-5293.

In embodiments, the system for producing an American Petroleum InstituteStandards Group III Base Stock from vacuum gas oil, can be configured asfollows with reference to the Figures: conduit 10 containing vacuum gasoil; a fresh hydrogen injector 26 injecting hydrogen and raisingpressure in the conduit 10 to maintain between 1000 and 1500 psig; arecycle hydrogen injector 35 injecting recycle hydrogen at an elevatedpressure and raising pressure to maintain pressure in the conduit 10between 1000 and 1500 psig; a first heater 30 fluidly connected to theconduit 10 and to a first hydrogen reactor 32 for increasing the vacuumgas oil in temperature to 450 degrees F. while simultaneously saturatingthe heated vacuum gas oil through a plurality of hydrogen reactorsconnected in series having a liquid hourly space velocity (LHSV)⁻¹through the hydrogen reactors of from 0.5 to 2.5, forming a saturatedheated base oil, a coproduct and contaminants.

Example 2

In this example of the method, a second heater 40 fluidly connects tothe first hydrogen reactor 32 and a second hydrogen reactor 42 forfurther increasing in temperature the vacuum gas oil; saturating theheated vacuum gas oil through a plurality of hydrogen reactors connectedin series having a liquid hourly space velocity (LHSV)⁻¹ through thehydrogen reactors from 0.5 to 2.5 forming a saturated heated base oil, acoproduct and contaminants.

A third heater 50 fluidly connects to the second hydrogen reactor 42 andto a third hydrogen reactor 52 increasing the temperature of the vacuumgas oil to a third temperature of 600 degrees F. at a pressure between1000 psig and 1500 psig.

A high pressure flash drum 60 connects to the third hydrogen reactor forseparating contaminants from the saturated heated base oil 62 andcoproduct 64 at a high pressure from 1000 psig to 1500 psig.

A recycle overhead 55 can be connected to the high pressure flash drum60, receiving high pressure recycle hydrogen and contaminants separatedfrom the saturated heated base oil in the high pressure flash drum.

A low pressure flash drum 70 connects to the high pressure flash drum,the low pressure flash drum 70 is used for decreasing the saturatedheated base oil and coproduct pressure to between 40 to 60 psig.

A mixing conduit 75 receives a petroleum derived product 20 having aviscosity index greater than 120. The mixing conduit 75 receives thesaturated heated base oil 62 and coproduct 64 combining with a petroleumderived product 20 having a viscosity index greater than 120, forming asaturated heated base oil mixture 77 with a combined boiling point rangefrom 450 degrees F. to 1050 degree F. as defined by ASTM D-86.

A fractionation tower 90 receives and fractionates the saturated heatedbase oil mixture 77 by receiving steam 108 to remove a light oilfraction 111 with a an initial boiling point less than 600 degreesFahrenheit while simultaneously refluxing a cooled light oil fraction111 during fractionating forming an American Petroleum InstituteStandards Group III Base Stock with less than 0.03 percent sulfur,greater than 90 percent saturates and a viscosity index greater than 120as defined by ASTM D-2270 and a viscosity range from 2 centistokes to 10centistokes as defined by ASTM D-445 with a boiling range from 600degrees Fahrenheit to 1050 degrees Fahrenheit as defined by ASTM D-86,and a cold crank viscosity (CCS) from 1200 centipoise to 5000 centipoiseat minus 25 degrees Celsius and as defined by ASTM D-5293.

Example 3

In this example, a second heater 40 fluidly connects to the firsthydrogen reactor 32 and a second hydrogen reactor 42 for furtherincreasing in temperature the saturated heated base oil, forming aheated saturated heated base oil, a coproduct, and contaminants.

A third heater 50 fluidly connects to the second hydrogen reactor 42 andto a third hydrogen reactor 52 increasing the temperature of the heatedsaturated heated base oil to a third temperature of 600 degreesFahrenheit at a pressure between 1000 psig and 1500 psig.

A high pressure flash drum 60 connects to the third hydrogen reactor 52for separating high pressure recycle hydrogen and contaminants from thesaturated heated base oil 62 and coproduct 64 at a high pressure from1000 psig to 1500 psig. A low pressure flash drum 70 connects to thehigh pressure flash drum, and is used for decreasing the heatedsaturated heated base oil and coproduct pressure to between 40 to 60psig.

A fourth heater 80 fluidly connects to the low pressure flash drum 70for heating the heated saturated heated base oil 62 and coproduct 64forming a heated saturated base oil having a boiling point from 450degrees Fahrenheit to 1050 degrees Fahrenheit as defined by ASTM D-86.

A fifth heater 85 can be used in this embodiment to preheat thepetroleum derived product 20 having a viscosity index greater than 120to a temperature between 400 and 600 degrees Fahrenheit.

A mixing conduit receives preheated petroleum derived product 20 and theheated saturated heated base oil 82 and coproduct 64 with a combinedboiling point range from 450 degrees Fahrenheit to 1050 degreesFahrenheit as defined by ASTM D-86.

In this embodiment, a fractionation tower 90 receives and fractionatesthe saturated heated base oil 82 with preheated petroleum derivedproduct 20 to remove a light oil fraction 111 with a an initial boilingpoint less than 600 degrees Fahrenheit while simultaneously refluxing acooled light oil fraction during fractionating forming an AmericanPetroleum Institute Standards Group III Base Stock with less than 0.03percent sulfur, greater than 90 percent saturates and a viscosity indexgreater than 120 as defined by ASTM D-2270 and a viscosity range from 2centistokes to 10 centistokes as defined by ASTM D-445 with a boilingrange from 600 degrees Fahrenheit to 1050 degrees Fahrenheit, and a coldcrank viscosity (CCS) from 1200 centipoise and 5000 centipoise at minus25 degrees Celsius and as defined by ASTM D-5293.

While these embodiments have been described with emphasis on theembodiments, it should be understood that within the scope of theappended claims, the embodiments might be practiced other than asspecifically described herein.

What is claimed is:
 1. A method for producing an American PetroleumInstitute Standards Group III base stock from vacuum gas oil derivedfrom used oil, comprising: a. combining a petroleum derived producthaving a viscosity index greater than 120 into a vacuum gas oil derivedfrom used oil forming a vacuum gas oil mixture with a combined boilingpoint range from 450 degrees F. to 1050 degree F. as defined by ASTMD-86; b. increasing temperature of the vacuum gas oil mixture to atemperature from 450 degrees Fahrenheit to 600 degrees Fahrenheit,forming a heated vacuum gas oil mixture while simultaneously increasingpressure on the heated vacuum gas oil mixture from 50 psig to a pressurefrom 1000 psig and 1500 psig by injection of hydrogen; c. saturating theheated vacuum gas oil mixture forming a first partially saturated heatedbase oil then a fully saturated heated base with hydrogen through aplurality of hydrogen reactors connected in series, having a liquidhourly space velocity (LHSV)⁻¹ through the hydrogen reactors from 0.5 to2.5; d. separating a saturated heated base oil from a recycle overheadat a high pressure from 1000 psig to 1500 psig; e. removing contaminantsfrom the saturated heated base oil producing contaminant free saturatedheated base oil; and f. fractionating the contaminant free saturatedheated base oil using steam to remove a light oil fraction with aninitial boiling point less than 600 degrees F. while simultaneouslyrefluxing, forming an API Standards Group III Base Stock 113 with lessthan 0.03 percent sulfur, greater than 90 percent saturates and aviscosity index greater than 120 as defined by ASTM D-2270 and aviscosity range from 2 to 10 centistokes as defined by ASTM D-445 with aboiling range from 600 degrees F. to 1050 degrees F. as defined by ASTMD-86, and a cold crank viscosity (CCS) between 1200 and 5000 centipoiseat minus 25 degrees C. and as defined by ASTM D-5293.
 2. The method ofclaim 1, comprising the step of exchanging energy from the AmericanPetroleum Institute Standards Group III Base Stock is with the feedstockvacuum gas oil reducing temperature of the American Petroleum InstituteStandards Group III base stock from 500 degrees Fahrenheit to 300degrees Fahrenheit using a feed effluent heat exchanger.
 3. The methodof claim 2, comprising the step of receiving a warm American PetroleumInstitute Standards Group III Base Stock from the feed effluent heatexchanger and cools 100 degrees Fahrenheit to 150 degrees Fahrenheit andcooling using a cooling water exchanger and transferring the cooledAmerican Petroleum Institute Standards Group III Base Stock to storageor transport.
 4. The method of claim 1, wherein hydrogen is injectedusing a fresh hydrogen injector comprising a nozzle that engages a flowcontrol valve further in communication with a flow meter and a highpressure pump and a hydrogen vaporizer for receiving liquid hydrogenfrom a liquid hydrogen reservoir.
 5. The method of claim 1, wherein eachhydrogen reactor increases the temperature of the saturated heated baseoil in each hydrogen reactor by a minimum of 5 percent.
 6. The method ofclaim 1, comprising using a metallic catalyst in each of the hydrogenreactors, wherein the metallic catalyst is selected from at least one ofthe group consisting of: cobalt, nickel, and molybdenum.
 7. The methodof claim 1, wherein the separating of the saturated heated base oil fromthe recycle hydrogen is performed using high pressure flash drum.
 8. Themethod of claim 1 comprising using a recycle hydrogen injector to injecthydrogen into a heated vacuum gas oil mixture which comprises: a recyclenozzle; a. a recycle flow meter connected to the recycle nozzle inseries; b. a hydrogen compressor connected to the recycle flow meter; c.a second stage knockout drum separating contaminated water; d. a firststage knockout drum separating contaminated water and naptha; e. a watercooled exchanger; f. a high pressure wash water injector providing apsig from 1400 to 1600 psig receiving water; and g. a recycle overheadconnected to the high pressure wash water injector.